Chapter 74 Week Forty-Four October 15, 2007

With the engine in place, it was now time to complete the assembly of the various engine components, but first I installed the clutch slave cylinder with the push rod provided in the Smitty conversion kit. It went in without any problem and lined up perfectly. The clutch pedal seemed to work smoothly. The bleeder extension pipe was attached to the bracket I made to support the pipe. Bleeding the slave cylinder will now be a much easier job. Thanks again to Mr. Finespanner – Doug Reid.

Slave cylinder bleeder extension 2

Just to fill the holes and to prevent anything from dropping in unexpectedly I went ahead and loosely fit the NGK Spark Plugs BP6ES, stock number 7333.

To make installation a little easier I attached the gear reduction starter to the engine prior to installation in the car, and it was now time to hook up the wiring. I shortened the heavy duty starter cable that connects the solenoid and the starter and secured it to the starter with rubber insulation boots attached. Since my intention is to still rely on the original starting configuration, that is, using the external solenoid, I connected the small wire on the starter to the terminal post also used to connect the cable from the solenoid.

Starter

The installation of the breather pipe and hoses was next on my list. Since I will be taking off the rocker cover for valve gap adjustment once the engine is started, I left the clamp to the “T” connection on the cover loose. The inlet heater hose from the heater to the heater control tap on the motor. While in that location I went ahead and connected the tachometer cable to the tach drive housing.

Breather Pipe 2

Tach Cable to Drive Gear

Others have suggested the addition of a PCV valve connecting the breather “T” to the intake manifold to assist in minimizing oil pressure leaks. I bought a little kit from the British Car Specialists that included the valve, rubber piping and a connector for the intake manifold. It will be interesting to see if it does aid in respiration.

The oil gauge flexible hose was connected next. It connects to a fitting on the block and to the steel oil line that connects to the back of the oil pressure/water temperature gauge.

Oil Pressure Line

 

The exhaust headers were next to be installed. These are Phoenix headers and the full big bore exhaust system was sourced from AH Spares. The headers fit perfectly without any adjustments. I had them Jet-Hot coated in the sterling finish to keep them looking nice and to improve thermal qualities. Stainless steel flexible pipe (1 7/8”) was used to connect the headers to the stainless steel silencer and the big bore tail pipes. The front hanger bracket is in the wrong place for a BT7, so I made a custom spacer for that hanger. The rear hanger worked just fine. I was pleased with the final installation of the system.

Headers 1

Headers 3

Rear Hanger 2

Middle Hanger

 

Tail Pipes 2

I assembled the intake manifold, heat shield and carbs to the Bloody Beast. Those lower mounting nuts are not easy to access! The stainless steel flexible fuel lines were connected to the steel fuel line and to the two SUs. I had to pull everything off the engine when I realized that I had not yet attached the manifold fuel drain pipes!! As it turned out they are very close to the header pipes, but after checking with a few people who are more informed about such matters than me, I think I am comfortable leaving them as they are. They should have been installed along with the vacuum line BEFORE the rest of the engine components!!!!

Front fuel drain line

Engine from above

Engine from right

Engine LH view

Engine front view

Chapter 5 – Disassembly

June 29, 2002

Final Interior Dismantling

Gearbox tunnel and extension cover. Both were rusted badly and were discarded. I learned later as I was fitting new parts that I should not have violated the restorer’s rule: Never throw anything away until the project is complete!

Gearbox tunnel and extension cover

Fresh Air cover plate and screen on left (driver’s) side. Three self threading screws.

Parcel tray on passenger side. Four self tapping screws on the firewall. Three self tapping screws on the right side wall. One screw and nut into left side to hanging support bar. Then removed the parcel support bar with one screw and nut at top.

Parcel Tray Support brace.

Steering Wheel Shaft Blanking Plate on the right side. Note larger “painted washers” and self tapping screws. Felt gasket found on reverse side of the plate.

Steering Wheel Blanking Plate

Steering Wheel Shaft Blanking Plate Felt Gasket

Two Blanking Screws into captive nuts in firewall on passenger side that just fill holes similar to the driver’s side. These were not painted.

Large Wiring Harness Rubber Grommet in center of firewall. Then removed firewall tarpaper in center of firewall. Note the rubber insulation around the heater box hole and along the seam that would otherwise leak air.

Heat Insulation (tar paper) on firewall

Firewall Grommet

Heater Channel Opening

Center Panel Firewall “Tarpaper.” After removing the firewall “tarpaper” that is in three pieces I numbered the holes:

#1 – Bonnet release rod grommet

#2 – Blank Cover grommet

#3 – Grommet

#4 – Brake Line clip

#5 – Grommet

#6 – Grommet

#7 – Nut

#8 – Nut

#9 – Brake Line Clip

#10 – 1 Nut, 2 grommets Wiper motor

#11 – 2 Nuts

#12 – Nut

#13 – Nut

#14 – Nut

#15 – Nut

#16 – Main wiring harness to dash

#17 – Blank Cover Grommet

#18 – Nut

#19 – Nut

#20 – Nut

#21 – Grommet 

Left Panel Firewall “tarpaper”:

#22 – H2O temp. line

#23 – Oil line

#24 – Nut

Small Blanking Rubber Grommets under the heater opening in firewall. 

Blanking Rubber Grommets

Right Bonnet Hinge cotter pin and 4 washers. The thin washers go closest to the hinge. The nuts go to the inside of the bonnet.

Bonnet Hinge Fixing

Bonnet Hinge

Speedometer Cable at “L” junction to the gearbox.

Speedometer Cable to Gearbox

Clutch Pedal from pedal bar – two nuts. The nuts go to the right side. Removed the Brake pedal from pedal bar – two nuts with nuts to the right side. I noticed at this point that some primatively cut spacers had been added to the pedals for a short-legged driver!

Clutch Pedal

Clutch Pedal Spacer

Pedal Spacers

Floor Dip Switch with two bolts to the fixed nuts in floor. 3 wires: red/blue, blue/white, all blue.

Dip Switch Wiring and Bracket

Dip Switch

Heater Vents on both driver and passenger side below dash. Four self tapping screws in each

Heater Fresh Air Vent Door

July 2, 2002

Engine

Fan and fan belt – Loosened 4 bolts and washers and removed the fan and fan belt.

Fan and Fan Belt

Wiring to the coil –  CB Terminal – White with black stripe from/to the distributor body and white with black stripe from harness that goes to the generator. SW Terminal – Large solid white wire from harness to generator.

Coil Wiring

Generator – Removed 2 bolts and nuts and adjusting bracket with self-locking nut. F Terminal – yellow/green stripe wire from harness. D Terminal – Large solid yellow wire connected to large spade.

Dynamo – Generator

Generator Adjustable Mounting Bracket

Generator Wiring

Distributor –  Removed two 7/16” bolts – note position of distributor and vacuum advance. Numbered each wire to the correct cylinder. Disconnect vacuum line and oil feed line to the tachometer drive.

Distributor Wiring

Distributor

Distributor Cap

Distributor Mounting Clamp

Oil Filter –  Removed two large bolts to the engine block.

Oil Filter Mount

Oil Filter

Starter and Solenoid  Disconnected solenoid to starter lead cable. Loosen two 9/16” bolts accessed through the interior bulkhead and under car.

Starter

Starter Solenoid

Starter Solenoid Wiring

Starter Cover

Engine mounts – Removed 4 bolts from right front to frame. Then removed left side.

Engine to frame Mount

Ground strap –  Disconnected the strap from the frame.

Oil pressure line –  Disconnected the line at top union near intake manifold.

Oil Pressure Line Disconnect

Breather pipe –  Disconnected the pipe at the “T” junction on the rocker cover.

Breather Pipe Disconnect